ASME Composite Carbon Fiber Autoclave

Описание продукта

1. Brief Introduction

In the last ten years we have seen the evolution of new materials, with excellent mechanical and physical features. The mechanical resistance, together with the lightness of composite materials, are finding more and more applications. We call composite material the product obtained from the polymerization of carbon fibers and resins, adequately prepared and shaped overlapping coats of fibers and resin on moulds or cores.

The autoclave is a key equipment for hot-pressing shaping of carbon fibers and resin matrix composites ( polyimide, bismaleimide, epoxy resin and thermoplastic resin matrices, etc. ), In fact, the quality of the product is obtained inside the autoclave reaching an increase of mechanical features up to 20-30% compared to other methods of polymerization, which do not foresee the outside pressurization of the product.

The reliability and the precision of the cycles which can be obtained with autoclave, allow to reach and keep high quality standards of the product, which is widely used in the high-tech fields such as aerospace, automotive, electronics, weapon, traffic, sports equipments and new type of energy, etc.

2. Basic Data

2-1. Model and Size of the Composite Autoclave

Ø Autoclave model: SN-CGF

Ø Effective diameter: according to customer

Ø Effective length: according to customer

Definition: * Effective diameter is the workable diameter of the autoclave.

* Effective length is to point to do the actual length of the composite material.

2-2. Production Performance

Ø Product size: max.according to customer

2-3. Electric Power

Ø Operating Voltage: according to customer

Ø Control Power: according to customer

Ø Total power: according to customer

2-4. Water and Air supply:

Ø Cooling water consumption: ~10m3/h

Ø Cooling water pressure: min.3 bar ~ max. 6 bar

Ø Control air of control equipment: 5 ~ 7bar

Ø Max. Nitrogen source for Autoclave: 15 bar

3. General feature and working process of the autoclave

3-1. General feature

Our Autoclave is a sealed pressure vessel which can be heated by a forced convection heating unit, where temperature, pressure and vacuum can be controlled effectively. By means of an advanced design, consisting of a forced convection fun and motor unit, output heating power system can be adjusted 0-100%,proportional control of the pressurization, cooling and exhaust components. It can obtain an uniform temperature and pressure according to the process curve. Temperature is check in heating, keeping, and cooling phase. The heating/cooling gradients can be set by operator. Pressure is adjusted in pressurization, keeping, release phase.

3-2. Working process

The whole working process of our Autoclave has 17(or more) segments .In each segment, the value of temperature, pressure, vacuum and segment time can be set and monitored by HIM and PC, and the operation process will be realized by our exclusively developed software which is based on PLC control system to ensure the full automatic operation. our Autoclave is suitable for manufacturing various composite materials, and it also can guarantee the perfect product quality.

Recipes for example:

Vacu1:minimum vacuum pressure Vac2: maximum vacuum pressure

Press.1: pre-pressure Press.2:final pressure

Temp1:temperature of first segment Temp2: temperature of second segment

Temp3: temperature of third segment Temp4: temperature of forth segment

Temp5: temperature of cooling and release

T1: keeping time of first segment T2:keeping time of second segment

T3: keeping time of third segment T4:keeping time of forth segment

(1) Put the blank of composite materials and the moulds into the vacuum bag, and then put into the autoclave together, finally, start to vacuum, getting the vacuum to the set point: Vacu1

(2) Start heating, Temperature rise to set point:Temp1, at the same time, pressurization, the pressure rise to set point: Press.1, and then starting the first keeping phase , the keeping time is the set point T1.

(3) Completed the first keeping phase, continue to heat, the temperature rise to set point: Temp2, vacuum to Vacu2 or atmospheric pressure, and then began to start the second keeping phase, the keeping time is the set point T2.

(4) Completed the second keeping phase,pressurization, the pressure rise to set point: Press.2.

(5) Continue to heat, temperature rise to set point: Temp3, began to start the third keeping phase, the keeping time is the set point T3.

(6) Completed the third keeping phase,continue to heat,the temperature rise to set point: Temp4,began to start the forth keeping phase, the keeping time is the set point T4.

(7) Completed the forth keeping phase,began to start the cooling stage,Until the temperature dropped to set point:Temp5.

(8) Air release

3-3. Recipe Preview

You can save and choose different recipe.

3-4. Control System Structure

3-5. Operation specifications

3-5-1 Pressure

Ø Pressurization Medium: Nitrogen

Ø Maximum working pressure::1.5Mpa (15bar)

Ø Maximum design pressure:1.6Mpa (16bar)

Ø Pressurization rate: 0-0.6bar/min average rate from 0 bar to max. working pressure.

Ø De-pressurization rate: 0-0.6bar/min average rates from max. working pressure to 0 bar.

3-5-2 Temperature

Ø Maximum working temperature:250℃

Ø Maximum design temperature of vessel:260℃

Ø Heating rate: 0-3°C/min based on average air temperature from ambient to 250°C and autoclave with 800Kgs PCM and 1500kgs steel.

Ø Cooling rate: 0-3°C/min based on average air temperature from 250°C to 50°C and autoclave with 800Kgs PCM and 1500kgs steel.

OLYMSPAN composite autoclave is different from the conventional autoclaves. It does not require a radial air-duct and instead utilizes the floor as the forward air delivery system. This unique design features decrease the cost for customer, and make the temperature more uniform.

Ø The Motor fan for circulation

The motor is bolted to the body of the autoclave, it drives the fan directly.

Ø Main parameters of circulating motor fan

Power:18.5KW,Frequency conversion control

Connecting format:direct-connected ,

Rated rotate speed:960r/min(400V/50HZ),

Fan wheel:6# centrifugal impeller,

wind pressure:1050Pa,

Flow rate:8900M3/h.

Ø Shaft sealing and cooling

Fully sealed special motor, bearings with SKF high-temperature series. The structure is easy to maintenance. Working use of water cooling, the shaft water cooling with separate water pump and flow switch to be fitted to monitor water flow and automatically alarm/stop the cycle if there is not enough water flow.

For composite curing applications with high volatile content (ie. high-temperature polyimides), the vacuum filter will be much more effective condensing volatiles and solvents during high-temperature curing operations.

4-11-7 Each vacuum source individually controlled, it can be done vacuum and vent. And each will be individual shut off in case of vacuum bag rupture.

4-11-8 Separation of vacuuming and measuring.

4-11-9 Automatic vacuum leakage test before start a circle.

4-12. Lightning System

Lightning throughout the autoclave working area, it is 400 lux.

4-13 Control System

Ø The Control System is developed based on the research and development toward composite material field, and it is made up of one PLC for the automatic managing of the process and one PC for the supervision of the system. The operation of the whole system is based on the exclusive developed software package-TPC(Thermal processing control).

Ø Password protected entry access, operator can log into the system by accessing the security login form with a name and password.

Ø According to the different working process requirement, it can set segment time, control TC, temperature value, temperature rate, vacuum value, pressure value, pressure rate, etc. before curing, and it also can modify the parameter on live operation.

Ø It can choose and save the different curing recipe, display a real time and historical trend of the pressure, vacuum and temperature; storage all processing data and its paperless record function can realize reporting of working curve and process parameters.

Ø It can monitor all actions of devices and the safety system information continuously, such as safety interlock, door closed, door locked and so on.

Ø It has audible and visual alarm system and diagnostic and fault finding screen, including over-temperature and over-pressure alarm and various safety protection functions, such as vacuum leakage, over cure cycle deviations, component failure, etc.

Ø Heating control will allow operator to control from product or air or minimal T/C reading, the TPC has control TC, operator can choose air TC, High TC, or low TC.

The autoclaves components and sensors will be monitored and controlled by the TPC control system. TPC is the Windows XP/Win 7 version of company computerized control software.

6-2 Superior Control is Your Key to Performance

Most will agree that in the world of composites manufacturing, the control system is a key component to assuring autoclave performance, usability, and reliability. Even the best autoclave will be crippled by a poor performing control system, especially when processing large volumes of composites. Because of this fact, we have focused a large portion of our R&D efforts on our control software and the features/capabilities that can improve processing performance, reliability, and lean manufacturing in autoclaves.

6-3 Sample Screen Images

The following screen images are provided for a typical OLYMSPAN composite autoclave implementation.

7.1 Air Storage tank for Nitrogen7.Assistant equipments for autoclave

7.1.1 Max. working pressure 1.5Mpa

Ø Installation mode: Vertical

Ø Capacity: 12M3

Ø Max pressure: 1.5 Mpa

Ø For the autoclave operating pressure:0.7Mpa

Ø Environment operation temperature: -10℃ - 50℃

Ø Manufacturing standard: GB150-2011, Chinese Pressure Vessel

7.1.2 Max. working pressure 3.0 Mpa

Ø Installation mode: Vertical

Ø Capacity: 8M3

Ø Max pressure: 3.0 Mpa

Ø For the autoclave operating pressure: 1.1 Mpa

Ø Environment operation temperature: -10℃ - 50℃

Ø Manufacturing standard: GB150-2011, Chinese Pressure Vessel

7.2 System of the water preparation

7.2.1 Water pump

Ø Capacity: 8t/h

Ø Head: 30M

Ø Power: 3phase, 380V, 1.5 KW

Ø Material: SUS304

7.2.2 Multi media filter

Ø Capacity: 5t/h

Ø Dimension: Φ1000×1800mm

Ø Material: glass fiber reinforced plastic

Ø Quantity:1pc

Ø Accessory: Pipes and valves

7.2.3 Activated carbon filter

Ø Capacity: 5t/h

Ø Dimension: Φ1000×1800mm

Ø Material: glass fiber reinforced plastic

Ø Quantity:1pc

Ø Accessory: Pipes and valves

7.2.4 Softening filter

Ø Capacity: 5t/h

Ø Dimension: Φ1000×1800mm

Ø Material: glass fiber reinforced plastic

Ø Quantity:1pc

Ø Accessory: Pipes and valves

7.2.5 Sensors, pipes, valves and Instruments

7.3 Circulating water cooling system

This section includes water pump, cooling tower, water tank, filters, valves and pipes.

Ø Type: Open cycle

Ø Quantity: 1 set

Ø Flow rate of pump: 10t/h

Ø Head of pump: 30m

Ø Flow rate of cooling tower: 15t/h

Ø Water tank volume:5cbm

7.4 Platform device , Trolley and installation material

7.4.1 Platform device is used for the loading trolley, it can be moveable.

7.4.2 Trolley is used for part loading and transport, the Length is 4 m. Material is carbon steel with 10 vacuum connections, 10measuring connections (vacuum), 20 connections for thermocouples

7.4.3 Valves , pipes ,flange, gasket and all material for installation of autoclave.

8,Configurations of composite autoclave

Ø PC: Dell

Ø PLC: Siemens

Ø Main electrical component : Schneider

Ø Shell: GB150-2011, CHANGZHOU,CHINA

Ø Heater : Electric heating inconel tubular heaters.

Ø Insulation material: Ceramic fiber

Ø Protect armor: Stainless steel

Ø Heating exchanger:304 stainless-steel, XUELANG, China

Ø SCR: SHIMADEN, China

Ø Electro-pneumatic adjustable ball valve: YAMATAKE, Japan

Ø PID controller : Omron ,Japan

Ø Limited Switch: Omron ,Japan

Ø Special Motor: CHANGZHOU, China

Ø Thermocouple: OMEGA

Ø Pressure transducer: KUNLUN, CHINA

Ø Vacuum pump: RUFUS.

9. Packing

9-1. The equipment will be properly packed / wrapped considering long-distance ocean and land transportation and rough handling that may happen in the absence of both parties.

9-2. Proper protection from moisture, rust, mold, scratches, shaking, etc, will be taken so that the goods may arrive at the installation site in good condition.

9-3. Shipping marks and warning signed will be clearly painted, and detailed packing list (in

English) will be soundly attached, to the outside of the packing.

10. Delivery, Installation and Quality Guarantee

10-1. Delivery

The delivery period is 80 days after receiving down-payment; but does not include shipping time!

10-2. Installation

10-2-1 The installation and commissioning takes 1 person x 20 days (max.) under Buyer`s assistance. Production training is carried out during the same period.

10-2-2 The international travelling cost, including round-trip air tickets, insurance, boarding and meals of the Seller`s service team should be charged to the buyer.

10-3. Quality Guarantee

The Seller provides 14 months quality guarantee, during which the Seller is responsible for all equipment failures due to inferior quality, improper design or services.

11. Workshop View

12 .PAYMENT TERM

The contract value shall be paid by the buyer to the seller in the following ways:

1. 30% of total value will be paid by T/T as down payment.

2. 70% on submission of approval drawings by T/T OR LC.

Alternate terms may be considered, though modification of terms may affect overall price of system.

After the contract working, we will execute each item and keep relevant standards strickly in every manufacturing process. Keep in touch with customer and make sure that craft, quality and technology could meet the requirements.

13.3 Service after sale:

Help customer for installation and training at site. Maintenance and repair for one year. Customer should pay for the round-trip flight ticket and accommodation.